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The blanking and forming of materials in cold condition is done in many different application such as; shearing, punching, cold forging, drawing,cold extrusion, rolling and powder pressing.

All applications include high mechanical forces and sliding contact between the tool surface and the work material. There are high demands on tool hardness to givewear resistance and resistance to plastic deformation. In order to improve the wear resistance further some of the cold work steel grades are highly alloyed givinghard particles (carbides) in the matrix. The combination of high hardness and hard carbides is however also impairing the machinability.

ASSAB can provide you with tool steels from a program of high quality tool steels covering all your demands. Low alloyed carbon tool steel grades, high-alloyedconventional metallurgy grades as well as powder metallurgical grades together with proper advice regarding tool steel selection and treatments.Depending on theapplication, the work material and the production series, a cold work tool steel program will contain grades with different combinations of:

• Wear resistance

• Resistance to plastic deformation

• Chipping resistance

• Total cracking resistance

• Good machinability and grind ability

GRADE CHEMCIAL COMPOSITION (%) Hardnesssupplied approx.

HB

Ref. STANDARD CHARACTER-ISTICS APPLICATIONS

C Mn Cr Mo V W Others AISI W.nr JIS

DF-2(DF-3)

0.95 0.5 0.1 0 .1 0.5 190 01 1.251 SKS3 General pu rpose tool stee l, good s urface hardness,wear resistance, easy to harden.

Cutting: blanking, punching, piercing, cropping, shearing, trimming,clipping. Forming: punching, raising, drawing, rim rolling, spinning,flow forming.

ASSAB 88 0,9 0,5 7,8 2,5 0 ,5 Si 0,9 235 Patented Mixed-abrasive profile and good resistance tochipping. Good machining and WEDM properties.

Blanking and fine blanking, shearing, forming, coining, cold forging,cold extrusion, thread rolling, drawing and deep drawing, powder 

pressing.

XW-5 2.050.8 12.5 1.1 240 D3/D6 1.2436 SKD2 High per formance too l s teel . Excellent abras ivewear resistance.

Blanking, punching, cropping, shearing, trimming, clipping.

XW-10 1.0 0.6 5.3 1.1 0.2 215 A2 1.2363SKD12 Good hardenabil ity and wear res is tance. Excellentsize stability. For medium runs.

Blanking, punching, piercing, cropping, shearing, trimming, clipping.

XW-41

(XW-42)

1.550.3 12.00.8 210 D2 1.2379SKD11High performance tool steel . High wear resistanceand toughness.

Blanking, fine-blanking, punching, cropping, shearing, trimming,clipping.

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 Hot work tools operate at elevated temperatures and form different products in e.g. aluminum, steel or other metals.

The most common application areas in hot work are die casting, extrusion and forging. The high working temperatures put very high demands on the tool steel. Theproperties' profile of material used for hot work should enclude an excellent hot strength as well as a very good ductility and toughness.

Other important tool steel properties are a high resistance against thermal cyclic stresses and a good hot wear resistance. The properties profile should be even in alldirections in the tool steel for best performance.

• Good strength at high temperatures

• High ductility and toughness

GRADE CHEMCIAL COMPOSITION (%) Hardnesssupplied

approx. HB

Ref. STANDARD CHARACTER-ISTICS APPLICATIONS

C Mn Cr Mo V Si Others AISI W.nr JIS

8407SUPREME

0.39 0.4 5.3 1.4 0 .9 1. 0 S-Max0.003

180 H13 1.2344SKD61Good resistance to thermal fatigue. The steel is produced by a specialmelting and refining technique in order to give mechanical propertieswith maximum isotropy and is certified to meet a minimum averageCharpy V-notch test result of 11 J.

Suitable for a wide variety of hot work applications,including tools for high pressure die casting, hotextrusion and press forging, 8407 SUPREME alsomeets or exceeds NADCA 207-97 specifications.

Dievar Cr-Mo-V alloyed hot work toolsteel

160 Patented High per formance hot work tool stee l w ith very good res is tance to heatchecking, gross cracking, hot wear and plastic deformation.

Excellent choice for die casting, forging and extrusion

8407 2M 0.39 0.4 5.3 1.4 0.9 1.0 185 H13 1.2344SKD61Hot work tool steel with overall good ducti li ty, toughness, wear resistance, hardenability and machinability. 8407 2M is speciallyprocessed to provide the best overall product consistency anduniformity available in a conventionally produced AISI H13 or JISSKD61 type of tool steel

Tools for extrusion, hot pressing, moulds for plastics.

QRO 90SUPREME

0.380.752.6 2.250.9 0.3 180 Patented Very good h igh temperature s trength and very good thermal fat igueresistance.

Die casting dies and associated tooling, extrusion diesand extrusion tooling, forging dies.

HOTVAR

Choosing the optimum mould material for best tooling and production economy.

When a new moulded part is to be produced many important decisions have to be made in order to fulfil all requirements set. Decisions will depend on plasticmaterial, production method, multi or single cavity number of parts to be produced, tolerance and surface finish.

oug ness. press ng, eep raw ng, n ves.

VANADIS 4EXTRA

1.4 0.4 4.7 3.5 3 .7 Si 0.4 230 Patented Powder tool steel for long run tooling, where highdemands on adhesive wear and chippingresistance, is required

Blanking, fine blanking and forming of thicker work material such asaustenitic stainless steel, mild carbon steels, UHSS, copper andaluminum

VANADIS 10 2.9 0.5 8.0 1.5 9.8 300 Patented Powder too l s teel . Supreme wear res is tance. Blanking and forming,f ine-blanking, b lank ing for e lect rical sheet , deepdrawing, cold forging, slitting knives, powder pressing.

CARMO 0.6 0.8 4.5 0.5 0 .2 240-270 Patented Prehardened tool steel with good weldability andflame-hardenability

Used in flame-hardened or in the through- hardened condition for blanking and forming of both car body parts (thin sheet) or structuralparts (thicker sheet).

ASP 23 1.28 4.2 5.0 3 .1 6 .4 260 M3:1 Powder HSS Excellent wear resistance andtoughness

Blanking of medium to high carbon steels, blanking of harder materials, plastic mould tooling, plastic processing parts

ASP 30 1.28 4.2 5.0 3 .1 6 .4 Co 8.5 300 Powder HSS for cutting tools. Excellent wear  resistance and toughness. Good hot hardness.

Suitable for chipforming multi-edge cutting tools and single-edgecutting tools. Cold work applicants where exacting demands are

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Eventually a decision will be made about suitable mould material to be use. ASSAB can help ensure that the final moulding result will be reached by recommendingoptimum the best mould material for the specific application. In our product program you will find a material suitable for your needs.

Right choice of tool materials for plastic moulding tools, should achieve:

• High surfaces finish

• Corrosion resistance

• Wear resistance

• High thermal conductivity

• Good surface finish after EDM or photoetching

GRADE CHEMCIAL COMPOSITION (%) Hardnesssupplied approx.

HB

Ref. STANDARD CHARACTER-ISTICS APPLICATIONS

C Mn Cr Mo V W Others AISI W.nr JIS

718HH 0. 37 1. 4 2 .0 0. 2 Ni 1.0

S<0.01340- 380 P-20

mod1.2738 Modified prehardened plastic mould steel. Very

good polishabilty.Injection moulds for themo-plastics, extrusion dies for thermo-plastics, blow moulds, forming tools, press- brake dies, structuralcomponents, shafts.

618 0.38 1 .4 2.0 0.2 Ni 1.0 290- 330 P-20mod

1.2738 Prehardened plastic mould steel. Goodpolishability and good machinability

Injection moulds for themo- plastics, extrusion dies for thermo-plastics, blow moulds, forming tools, machine components.

Polmax 

0,38 0 ,5 1 3,6 0,3 Si 0,9 200 Excellent polishability. Good resistance tocorrosion and wear. Good machinability.

Recommended where extreme surface finishes are required, suchas lens moulds and CD moulds.

STAVAX ESR 0.38 0.5 13.6 0.3 200 420mod

1.2083 Stainless plastic mould steel with excellentpolishability and corrosion resistance.

Corrosion/staining resistance, wear resistance, high surface finish.

STAVAXSupreme

Cr-Ni-Mo-V alloyed 250 AISI420mod

Stainless mould steel with a unique combinationof toughness, corrosion resistance and through-hardening properties.

For all type of moulds, especially suited for larger tools wherecorrosion in production is unacceptable and where high surfacefinish is required.

ELMAX 1.7 0. 318.0 1. 03 .0 240 Powder tool st eel. St ainless p lastic mould stee lwith high wear resistance.

Electronics industry: connectors, plugs, switches, resistors,integrated circuits. Food processing industry: corrosion resistance

and wear resistance.RAMAX 2 0.28 1.116.7 S 0.12 300- 340 Stainless steel for holder blocks with excellent

machinability and corrosion resistance.Holders/bolsters for plastic moulds, plastic and rubber moulds withlow requirements on polishability, dies for plastic extrusion andconstructional parts.

PRODAX Tooling Aluminium 145 Aluminum for plastic moulds, blow moulding andvacuum moulding

Blow moulding, vacuum forming, foam moulding, rubber moulds,footwear moulds, injection moulds, RIM-forming, jigs and fixtures,bolsters and holders.

CALMAX 0.6 0.8 4.5 0.5 0 .2 200 Patented High toughness, good wear resistance and goodpolishability steel for plastic moulds.

Typical blanking die where it could be used because of the highdemands on otughness. Mould for the production of electricalcomponents.

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CORRAX 0.030.312.0 1.4 Ni 9.2 Mo1.4 AI 1.6

32 HRC Patented Age hardening stainless steel with superior corrosion resistance.

Injection moulds for corrosive plastics, rubber, medical and foodindustry; Extrusion dies; Plastic processing (screws, nozzles);Engineering parts.

MOLDMAXLH/MM

Tooling Be ryllium Copper LH 30 HRC

MM 40 HRC

Beryllium copper for plastic moulds. Excellent heatconductivity.

Blow moulds: pinch offs, neck rings and handle inserts. Injectionmoulds: moulds, cores, and inserts.

MOLDMAX XL Tool ing Bery ll ium Copper  9Ni 6Sn Balance Cu

28 – 32 HRC Copper alloy with high thermal conductivity andhigh strength

Primarily for core inserts in larger injection moulds.

PROTHERM Tooling Beryllium Copper 190 Beryllium copper for plastic moulds. Extremelyhigh thermal conductivity.

Injection moulds, blow moulds, cores and inserts for all plastics,including corrosive grades. Nozzle tips, gates and manifolds for hotrunner systems.

EM33 Micro alloyed steel 280-340 Prehardened plastic mould and holder steel withexcellent toughness and machinability.

Plastic and rubber moulds, support plates and constructional parts.Stripper plates in blanking application. Holders/bolsters for plasticmoulds and die casting dies.

EM38 Micro alloyed steel 350 - 410 Prehardened plastic mould steel with highhardness

Injection moulds and extrusion dies for thermoplastics. Rubber moulds and blow moulds. Stripper plates in blanking application

 

We can supply a large variety of standardized machinery steels in flat, round and square sections.

The programme includes steels with highly improved machinability for high productivity.

GRADE CHEMCIAL COMPOSITION(%)

Hardness suppliedapprox. HR

Ref. STANDARD CHARACTER-ISTICS APPLICATIONS

C Mn Cr Mo V AISI W.nr JIS

705 0.35 0 .70 1 .40 1 .40 0. 20 275 - 335 4340 1.6582 SNCMB H igh st rength m ach ine ry s teel .Suitab le f or  induction and flamehardening

Suitable for induction hardening and can be nitrided or tuffrided to a surfacehardness of 600-650 Vickers.

709 0.42 0 .75 1 .05 0. 20 245 - 290 4140 1.7225 SCM4 Alloy ed mach inery steel suit ab le fo r inducti onand flamehardening

Suitable for flame and induction hardening and can be nitrided or tuffrided toa surface hardness of 600 - 650 Vickers.

7210 0.15 0.90 0.80 1.20 0.10 Max. 217 3115 SNC21 Alloyed case hardening steel. For applications requiring a hard, wear resistant surface and a tough core,such as transmissions components for the automotive industry.

760 0.45 0 .70 210 1045/1050

1.1730 S50C General utility machinery steel for partsrequiring wear resistance at low loads.

Punch holders (jigs), die holders (fixtures) guide plates (simple bendingdies), backing plates (simple structural components).

707 

0.25 0.75 1.05 0.20 215- 260 4130 1.7218 SCM2 Alloyed machinery steel suitable for welding Used for shafts, gears, sprockets, etc., particularly when weldability isrequired.

 

Martempering 

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| A | B | C | D | E | F | G | H | I | J | K | L | M | N | O | P | Q | R | S | T | U | V | W | X | Y | Z |

Definition: A heat treatment involving austenitisation followed by step quenching, at a rate fast enough to avoid the formation of ferrite,pearlite or bainite to a temperature slightly above the Ms point. Soaking must be long enough to avoid the formation of bainite. Theadvantage of martempering is the reduction of thermal stresses compared to normal quenching. This prevents cracking and minimisesdistortion.

PRESS CAPACITY CALCULATIONS 

Go to spreadsheet 

BLANKING 

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Where F(b) = Blanking force (kN), P = Perimeter of blank (mm), S(s) = Shear strength (MPa), c = a constant for impact loadings.

Grinding a shear angle on a punch minimises the shock load on a press and gives a quieter punch operation. For zero shear, when s = 0, c = 1.25. For part shear,when s = 0.3t, c = 1.0. For full shear, when s = t, c = 0.75. (NB: on a small diameter, multi-punch set-up, staggering the length of punches gives a similar effect onshock loads.) e.g. 150mm diameter blank in 3mm mild steel with part shear on punch gives:

 

DRAWING 

Where F(d) = Drawing force (kN), P = Perimeter of draw (mm), S(y) = Yield strength (MPa), b = a constant for non-draw areas, d = a factor to be used when using a die cushion.

When drawing circles, b = 1.0. When drawing irregular forms, corners are non-draw areas and b should be reduced by 0.1 for each corner where the radius is lessthan 0.3 times the length of the shortest adjacent side. e.g. 150 x 50 pan with 10mm radius corners in 1.6mm mild steel.

 

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Blanking ForceEnter data

Quantity of blanks or holes

Either Diameter of blank or hole mmOr Width of blank or hole mm

Length of blank or hole mm

Or Perimeter of blank (if known) mm

Thickness of material mm

Shear strength of material 320 Mpa

Shear factor for punch or die full shear  

(place a 1 in only one box) 1 part shear  

  no shear 

Force required for blanking 0 tons

Drawing ForceEnter data

Perimeter of draw mm

Thickness of material mm

Yield strength of material 310 Mpa

No of "corners" *

Die cushion (1 for yes)

Force required for drawing 0 tons

* only count a "corner" if its radius is < 0.3 x length of shortest adjacent side

PIN AND BUSH CALCULATIONS

NB: The following calculations allow for 0.25 inches die re-grind allowance. If a greater allowance is required, reduce pin and bush lengths accordingly.

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MAX PIN LENGTH = Shut height -- 0.5 inches

MAX BUSH LENGTH = Shut height -- Bottom plate thickness -- 0.75 inches

MIN BUSH LENGTH = Shut height + Stroke -- Pin length + 0.5 inches

NB: Where min bush length is greater than max bush length, the bushes leave the pins. In this instance, the maximum dimension takes preference.

TYPICAL MATERIAL STRENGTHS - MPa  Yield Shear     Yield Shear  

Mild Steel Hot rolled 310 320 Aluminium   120 140

  Cold rolled 260 290 Copper     70 180

Stainless Annealed 280 620 Zinc   --- 120

  Half hard 750 850 Brass Soft 100 220

  Full hard 950 1050   Hard 350 290